Self-adjusting machine vision detection device

Abstract

The invention discloses a self-adjusting machine vision detection device, and belongs to the technical field of machine vision detection. The device comprises an image acquisition module, an adjusting mechanism, a control module and a supporting frame. The image acquisition module is used for acquiring image information of a to-be-detected workpiece; the adjusting mechanism comprises a position adjusting assembly and an angle adjusting assembly, and can realize the position movement of the image acquisition module in the X-axis, Y-axis and Z-axis directions and the adjustment of the image acquisition module around the Z-axis and the pitching angle; the control module receives the image information and controls the adjusting mechanism to act; the supporting frame plays a stable supporting role. The device can automatically, accurately and quickly adjust the position and angle of the image acquisition module, meets the detection requirements of workpieces with different specifications, and improves the detection efficiency and accuracy.

Description

Technical Field

[0001] This invention relates to the field of machine vision inspection technology, and in particular to a self-adjusting machine vision inspection device, which can be widely used in the workpiece quality inspection process in multiple industrial fields such as electronics manufacturing, automotive parts production, and machining. Background Technology

[0002] Currently, machine vision inspection devices are widely used in industrial production for workpiece quality inspection, such as detecting dimensional deviations, surface defects, and assembly conformity. However, existing machine vision inspection devices often require manual adjustment of the image acquisition device's position and angle when inspecting workpieces of different specifications. This is not only cumbersome and time-consuming, but also difficult to guarantee in terms of adjustment accuracy, easily leading to inspection errors and affecting product quality judgment. For example, when inspecting a batch of cylindrical workpieces of different heights, workers need to constantly adjust the camera height to ensure that each workpiece is clearly imaged, a process that severely impacts production efficiency.

[0003] Furthermore, some automatically adjusting machine vision inspection devices have complex adjustment mechanisms and limited adjustment ranges, making them difficult to adapt to diverse inspection needs. Their slow response speed also fails to meet the requirements of high-efficiency production. Some devices can only adjust their position in the X and Y axes, rendering them ineffective for workpieces requiring Z-axis adjustment. Other devices have limited angle adjustment ranges, making it difficult to find the optimal shooting angle for irregularly shaped workpieces. Therefore, there is an urgent need for a machine vision inspection device capable of automatic, precise, and rapid adjustment. Summary of the Invention

[0004] Purpose of the invention: The purpose of this invention is to provide a self-adjusting machine vision inspection device to solve the problems of inconvenient adjustment, low accuracy, low efficiency and poor adaptability of existing machine vision inspection devices, so as to achieve efficient and accurate inspection of workpieces of different specifications and shapes.

[0005] Technical solution

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A self-adjusting machine vision inspection device includes an image acquisition module, an adjustment mechanism, a control module, and a support frame.

[0008] Image acquisition module: Used to acquire image information of the workpiece to be inspected, including a camera, lens, and light source. The camera and lens are connected, employing a high-resolution industrial camera, and the lens is a zoom lens with adjustable focal length, capable of adjusting the focal length according to the size and distance of the workpiece to ensure image clarity. The light source is positioned around the lens to provide sufficient and uniform light for image acquisition, avoiding image blurring and loss of detail due to insufficient or uneven lighting.

[0009] Adjustment mechanism: used to adjust the position and angle of the image acquisition module, including position adjustment component and angle adjustment component.

[0010] Position adjustment components: These components enable the image acquisition module to move in the X, Y, and Z axes. X-axis adjustment utilizes a ball screw and guide rail structure; motor one drives ball screw one to rotate, causing the image acquisition module to slide on guide rail one. Y-axis adjustment similarly uses a ball screw and guide rail structure; motor two drives ball screw two to rotate, causing the X-axis adjustment structure and image acquisition module to slide on guide rail two. Z-axis adjustment is similar; motor three drives ball screw three to rotate, causing the Y-axis adjustment structure, X-axis adjustment structure, and image acquisition module to slide on guide rail three.

[0011] Angle adjustment component: It adopts a rotary table structure. Motor 4 drives the rotary table to rotate, realizing 360-degree continuous rotation. The image acquisition module is installed on the rotary table to realize angle adjustment around the Z-axis. At the same time, a pitch adjustment structure is set on the rotary table. Motor 5 drives the pitch adjustment structure to adjust the pitch angle of the image acquisition module.

[0012] Control Module: A PLC controller is used, electrically connected to both the image acquisition module and each motor in the adjustment mechanism. The control module incorporates image analysis algorithms to process the image information transmitted from the image acquisition module, including image preprocessing, feature extraction, and dimensional measurement. After analysis and processing, based on preset detection parameters or image analysis results, control signals are sent to each motor to control the adjustment mechanism for corresponding position and angle adjustments. The control module is also equipped with a touchscreen for setting detection parameters and displaying detection results.

[0013] Support frame: Constructed from profiles, used to install and support components such as position adjustment components and angle adjustment components, ensuring the stability and structural strength of the entire device.

[0014] Compared with existing technologies, automatic adjustment is achieved: through the cooperation of the control module and the adjustment mechanism, the position and angle of the image acquisition module can be automatically adjusted according to the information obtained by the image acquisition module, without manual intervention, which greatly shortens the preparation time before detection and improves detection efficiency.

[0015] High adjustment precision: The use of ball screws, guide rails, and motor drive ensures the precision of position and angle adjustment, reduces detection errors, and improves the accuracy of detection results.

[0016] Highly adaptable: It can perform a wide range of position adjustments in the X, Y, and Z axes, as well as 360-degree adjustment around the Z axis and a wide range of pitch angles, to meet the inspection needs of workpieces of different sizes and shapes, including cylindrical, square, and irregular shapes.

[0017] Stable and reliable structure: The support frame is constructed with profiles, making it sturdy and able to withstand the weight of each component and the forces generated by its movement. Each adjustment component adopts a mature mechanical structure, ensuring reliable operation and a long service life.

[0018] Easy to operate: The control module is equipped with a touch screen, which allows operators to easily set detection parameters and view detection results without the need for professional programming knowledge, thus reducing the difficulty of operation. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0020] Figure 2 This is a schematic diagram of the image acquisition module of the present invention;

[0021] Figure 3 This is a schematic diagram of the adjustment mechanism of the present invention;

[0022] Figure 4 This is a schematic diagram of the control module of the present invention;

[0023] Figure 5 This is a schematic diagram of the support frame of the present invention.

[0024] In the diagram: 1. Image acquisition module; 11. Camera; 12. Lens; 13. Light source; 2. Adjustment mechanism; 21. Position adjustment component; 211. Motor 1; 212. Ball screw 1; 213. Guide rail 1; 214. Motor 2; 215. Ball screw 2; 216. Guide rail 2; 217. Motor 3; 218. Ball screw 3; 219. Guide rail 3; 22. Angle adjustment component; 221. Motor 4; 222. Rotary table; 223. Motor 5; 224. Pitch adjustment structure; 3. Control module; 4. Support frame; 5. Worktable. Detailed Implementation

[0025] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0026] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and therefore the scope of protection of the invention is not limited to the specific embodiments disclosed below.

[0027] Example 1: Inspection of cylindrical workpieces

[0028] When inspecting a cylindrical workpiece, the operator places the workpiece stably on the worktable (5) in the inspection area. The surface of the worktable (5) is flat and fixedly connected to the support frame (4) to ensure that the workpiece will not be displaced during the inspection process.

[0029] The camera (11) in the image acquisition module (1) first acquires an initial image of the workpiece. During the acquisition process, the lens (12) automatically adjusts the focal length according to the approximate distance of the workpiece, and the light source (13) emits stable light to illuminate the surface of the workpiece. The acquired initial image information is transmitted to the control module (3) in real time through a dedicated data transmission line.

[0030] After receiving the initial image, the control module (3) immediately starts the built-in image analysis algorithm to process it. First, image preprocessing is performed to remove noise interference and enhance image contrast. Then, feature extraction is performed to accurately identify the contour and axis of the workpiece. Through analysis, it was found that the axis of the workpiece and the optical axis of the camera (11) have a certain angle, which causes the workpiece to be tilted in the image. At the same time, the position of the workpiece in the image is off-center, which affects the accuracy of subsequent detection.

[0031] In response to the above situation, the control module (3) quickly sends out a series of control signals: Motor 4 (221) starts after receiving the signal, driving the rotary table (222) to rotate slowly. The rotation of the rotary table (222) adjusts the angle of the image acquisition module (1) around the Z-axis, so that the optical axis of the camera (11) gradually becomes parallel to the axis of the workpiece. While the rotation is being adjusted, Motor 5 (223) drives the pitch adjustment structure (224) to make fine adjustments to the pitch angle of the image acquisition module (1) until the optical axis is completely parallel to the axis.

[0032] In terms of position adjustment, the control module (3) calculates the displacement to be adjusted based on the distance of the workpiece deviating from the center obtained from image analysis. Then, it controls motor one (211) and motor two (214) to operate respectively. Motor one (211) drives ball screw one (212) to rotate, causing the image acquisition module (1) to slide along the X-axis direction on guide rail one (213); motor two (214) drives ball screw two (215) to rotate, causing the X-axis adjustment structure and image acquisition module (1) to slide along the Y-axis direction on guide rail two (216). Through the coordinated adjustment of the X-axis and Y-axis directions, the workpiece is accurately adjusted to the center position of the image. If the size of the workpiece in the image is found to be unsuitable during the detection process, the control module (3) will control motor three (217) to operate, drive ball screw three (218) to rotate, causing the related structure and image acquisition module (1) to move along the Z-axis direction on guide rail three (219), adjusting the height of the image acquisition module (1) so that the workpiece presents the optimal size in the image.

[0033] Throughout the adjustment process, the image acquisition module (1) continuously acquires images in real time and transmits them to the control module (3). The control module (3) continuously corrects the control signal based on the real-time images to ensure the accuracy of the adjustment. When the image acquisition module (1) reaches the optimal detection position and angle, the device begins formal inspection work, comprehensively inspecting defects such as diameter error and surface scratches on the workpiece. The final inspection results are clearly displayed on the touch screen of the control module (3) for easy viewing by the operator.

[0034] Example 2: Inspection of square workpieces

[0035] When inspecting a square workpiece, the operator places the workpiece on the workbench (5) in the inspection area. The square workpiece needs to be fully inspected for the flatness of multiple surfaces and the chamfering of the edges and corners.

[0036] The image acquisition module (1) first performs initial image acquisition on one surface of the workpiece. During acquisition, the lens (12) is adjusted to a suitable focal length, and the light source (13) provides uniform illumination to ensure that surface details are clearly visible. The acquired image information is sent to the control module (3) via a data line.

[0037] After analyzing the initial image, the control module (3) found that due to the structural characteristics of the square workpiece, the current shooting angle can only capture part of the surface of the workpiece, and the chamfer details of the corners are not clear enough in the image, which cannot meet the detection requirements.

[0038] To solve this problem, the control module (3) immediately controls the angle adjustment component (22): motor four (221) drives the rotary table (222) to rotate, causing the image acquisition module (1) to rotate around the Z-axis by a certain angle, so that the lens (12) can accurately align with the side of the workpiece that was not captured; at the same time, motor five (223) drives the pitch adjustment structure (224) to adjust the pitch angle of the image acquisition module (1), change the shooting angle, and make the chamfered part of the corner clearly presented in the image, which is convenient for subsequent detection of the size and smoothness of the chamfer.

[0039] In terms of position adjustment, since the positions of different surfaces of the square workpiece differ in space, the control module (3) controls the operation of motor one (211) and motor two (214) according to the position information of each surface. Through the movement in the X and Y axes, the image acquisition module (1) is precisely aligned with the center of each surface to be detected. If a surface is displayed too small in the image, which is not conducive to flatness detection, the control module (3) will control motor three (217) to drive the Z axis adjustment, reduce the height of the image acquisition module (1), and magnify the workpiece surface image, thereby more accurately detecting the flatness of the surface.

[0040] After the inspection of one surface is completed, the control module (3) continues to control the adjustment mechanism (2) to drive the image acquisition module (1) to adjust and inspect the position and angle of other surfaces in sequence according to the preset inspection sequence. During the inspection process, the inspection data of each surface is stored in real time in the storage module connected to the control module (3) until all the parts that need to be inspected have been inspected. Finally, the control module (3) summarizes and organizes the inspection results of each surface and displays them on the touch screen in an intuitive way, so that the operator can clearly understand the overall quality status of the workpiece.

[0041] In the description of this specification, the terms "connection," "installation," and "fixing," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0042] In the description of this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0043] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A self-adjusting machine vision inspection device, characterized in that, It includes an image acquisition module (1), an adjustment mechanism (2), a control module (3), and a support frame (4); The image acquisition module (1) is used to acquire image information of the workpiece to be inspected; The adjustment mechanism (2) is used to adjust the position and angle of the image acquisition module (1); The control module (3) is electrically connected to the image acquisition module (1) and the adjustment mechanism (2) respectively, and is used to receive image information and control the action of the adjustment mechanism (2); The support frame (4) is used to install and support components such as the adjustment mechanism (2).

2. The self-adjusting machine vision inspection device according to claim 1, characterized in that, The image acquisition module (1) includes a camera (11), a lens (12) and a light source (13). The camera (11) is connected to the lens (12), and the light source (13) is arranged around the lens (12).

3. The self-adjusting machine vision inspection device according to claim 1, characterized in that, The adjustment mechanism (2) includes a position adjustment component (21) and an angle adjustment component (22); the position adjustment component (21) can realize the movement of the image acquisition module (1) in the three directions of X, Y and Z axes; the angle adjustment component (22) can realize the angle adjustment and pitch angle adjustment of the image acquisition module (1) around the Z axis.

4. The self-adjusting machine vision inspection device according to claim 3, characterized in that, In the position adjustment component (21), the adjustment in the X-axis direction adopts a ball screw and guide rail structure. Motor 1 (211) drives ball screw 1 (212) to rotate, causing the image acquisition module (1) to slide on guide rail 1 (213). The adjustment in the Y-axis direction adopts a ball screw and guide rail structure. Motor 2 (214) drives ball screw 2 (215) to rotate, causing the X-axis adjustment structure and image acquisition module (1) to slide on guide rail 2 (216). The adjustment in the Z-axis direction adopts a ball screw and guide rail structure. Motor 3 (217) drives ball screw 3 (218) to rotate, causing the Y-axis adjustment structure, X-axis adjustment structure and image acquisition module (1) to slide on guide rail 3 (219).

5. The self-adjusting machine vision inspection device according to claim 3, characterized in that, The angle adjustment component (22) adopts a rotary table (222) structure. Motor 4 (221) drives the rotary table (222) to rotate. The image acquisition module (1) is installed on the rotary table (222). The rotary table (222) is provided with a pitch adjustment structure (224). Motor 5 (223) drives the pitch adjustment structure (224) to move.

6. The self-adjusting machine vision inspection device according to claim 1, characterized in that, The control module (3) adopts a PLC controller and is electrically connected to each motor in the image acquisition module (1) and the adjustment mechanism (2).

7. The self-adjusting machine vision inspection device according to claim 2, characterized in that, The light source (13) is a ring-shaped LED light source, and the brightness of the ring-shaped LED light source can be adjusted by the control module (3).

8. The self-adjusting machine vision inspection device according to claim 4, characterized in that, The first motor (211), the second motor (214), and the third motor (217) are all servo motors, and each servo motor is equipped with an encoder to provide real-time feedback of the motor's rotation angle information to the control module (3).

9. The self-adjusting machine vision inspection device according to claim 1, characterized in that, The support frame (4) is made of aluminum alloy and the surface of the support frame (4) has been anodized.

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